Clean room food processing systems, methods and structures

ABSTRACT

Some food pathogens are not well controlled by lethality treatments followed by refrigeration. A food processing facility according to this invention reduces the likelihood that food pathogens will be able to enter the food processing facility, or spread should they be able to enter. The food processing facility is divided into a plurality of area, with different areas having different allowed actions that can be taken on the food product, different rules and/or procedures for persons who are allowed entry, and/or different levels of cleanliness. The food processing facility includes a plurality of separate rooms for processing the food product, each including separate food processing machines, air handling systems, drain systems and/or often-used supplies and tools. Different air pressures within different areas limit the possible movement of airborne food pathogens. Sanitizing stations are placed between various ones of the different areas.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.13/246,027 filed Sep. 27, 2011 entitled CLEAN ROOM FOOD PROCESSINGSYSTEMS AND STRUCTURES, which is a continuation of U.S. application Ser.No. 12/769,388 filed Apr. 28, 2010 entitled CLEAN ROOM FOOD PROCESSINGSYSTEMS, METHODS AND STRUCTURES, now abandoned, which is a continuationof U.S. application Ser. No. 10/818,944 filed Apr. 6, 2004 entitledCLEAN ROOM FOOD PROCESSING SYSTEMS, METHODS AND STRUCTURES, now U.S.Pat. No. 7,707,931 issued May 4, 2010, each of which are incorporatedherein by reference in their entirety.

BACKGROUND OF THE INVENTION

Field of the Invention

This invention is directed to systems, methods and structures forreducing the likelihood of contamination of processed foods by bacteria,other microorganisms, or other pathogens.

Related Art

As food quality, sanitation and refrigeration practices have becomebetter, the presence in processed foods of most common bacteria thataffect food safety has been substantially reduced. While this hasimproved food safety overall, it presents the opportunity for moremarginalized, less common bacteria and other food pathogens, which areotherwise unable to compete with such more common bacteria, toproliferate and colonize food product(s) as they are processed. Forexample, Listeria monocytogenes (hereafter “LM” or “Listeria”), which isinhibited by competition from more common bacteria, and thus naturallyprevented from reaching fatal concentrations, is sometimes able tocolonize food product(s) as they are being processed. Because Listeria,unlike more common bacteria and other food pathogens, is able to growwell in refrigerated conditions, and because most, if not all, competingbacteria have been eliminated from the food product(s) being processed,there is little or no competition to the Listeria bacteria to keep itfrom growing to fatal concentrations when Listeria contaminates food.

At the same time, the U.S. government has instituted numerous programsand testing regimes to ensure that food products are pathogen-free,i.e., are not adulterated. For example, the presence of a food pathogenon a ready-to-eat meat product renders the meat product adulteratedunder the provisions of the Meat Inspection Act and/or the PoultryInspection Act. If adulterated, the ready-to-eat meat product cannot beshipped. Additionally, if the ready-to-eat meat product has already beenshipped, it must be recalled. Moreover, in most, if not all,conventional food processing facilities, even if the source ofadulteration of a particular lot of food product can be traced to asingle processing element, such as a food slicer, in that foodprocessing facility, it is difficult, if not impossible, to determinewhich particular food items may have come in contact with that source ofadulteration. As a result, the typical recall involves all productspassing through a food processing facility during the time of potentialadulteration to ensure that no adulterated food product remainsavailable for sale to the ultimate consumer.

The U.S. Department of Agriculture (USDA) has determined, for example,that Listeria is a hazard reasonably likely to occur in a slicingoperation. Slicing operations are relatively high risk becausepathogenic Listeria monocytogenes is ubiquitous and grows atrefrigerated temperatures. Thus, because Listeria is ubiquitous, it isvery difficult to prevent Listeria from colonizing processed foodproduct(s) at points between an upstream lethality treatment and adownstream packaging operation, such as at a slicing operation.Furthermore, because sliced meats are “ready-to-eat”, they are typicallyremoved from packaging and consumed without any consumer-appliedlethality treatment, such as cooking.

SUMMARY OF THE DISCLOSURE

Bacteria and other food pathogens that are not well controlled by thecurrent regimes of lethality treatment followed by refrigeration, suchas Listeria, provide significant challenges in preparing and packagingprocessed food product(s) so they do not become adulterated. Forexample, common industry practice is to have multiple food processingdevices, such as slicers, and multiple downstream packaging machines inthe single food processing room of the food processing facility.However, this provides a chance for contamination by bacteria or otherfood pathogens spreading from machine to machine by migration across wetfloors, through the air for microorganisms, such as Listeria, that areable to aerosol and float around on water droplets in the air, by foodprocessing and supervisory personnel moving from one machine to anotherin the single processing room, by food processing personnel movingfreely from one food processing room to another, and/or by maintenancepersonnel working on multiple similar and dissimilar machines within asingle food processing area or freely moving between separate foodprocessing areas.

This invention provides food processing facilities, systems and methodsthat reduce the ability of bacteria and other food pathogens to spreadfrom outside of the facilities into and through the facilities tocontaminate food processing machinery and food being processed withinthe facility.

This invention separately provides food processing facilities, systemsand methods which place one or more food processing machines and one ormore associated packaging machines forming a single set of foodprocessing devices in a separate food processing room.

This invention separately provides food processing facilities, systemsand methods that reduce the ability of food pathogens to migrate from acontaminated location or machine and/or from outside of the facility toan uncontaminated location or machine by controlling the movement ofpersons between unsecure, semi-secure and secure portions of the foodprocessing facility.

This invention separately provides food processing facilities, systemsand methods that reduce the ability of food pathogens to migrate from acontaminated location or machine and/or from outside of the facility toan uncontaminated location or machine by limiting food processingpersonnel to working in a single food processing rooms containing asingle set of food processing devices.

This invention separately provides food processing facilities, systemsand methods that reduce the ability of contamination to migrate from anadulterated location or machine and/or from outside of the facility toan unadulterated location or machine by limiting the movement of foodprocessing personnel between food processing rooms containing a singleset of food processing devices.

This invention separately provides food processing facilities, systemsand methods that reduce the ability of contamination to migrate from anadulterated location or machine and/or from outside of the facility toan unadulterated location or machine by controlling the movement ofmaintenance personnel between food processing rooms.

This invention separately provides food processing facilities, systemsand methods that reduce the ability of contamination to migrate from anadulterated location or machine and/or from outside of the facility toan unadulterated location or machine by separately providing at leastcommonly-used maintenance materials in each separate food processingroom.

This invention separately provides food processing facilities, systemsand methods that reduce the ability of contamination to migrate from anadulterated location or machine and/or from outside of the facility toan unadulterated location or machine by placing each set of one or morefood processing devices and one or more associated packaging devices ina separate high-pressure area such that air flows from the high-pressureareas into areas adjacent to the high pressure areas.

This invention separately provides food processing facilities, systemsand methods that reduce the ability of contamination to migrate from anadulterated location or machine and/or from outside of the facility toan unadulterated location or machine by providing separate foodprocessing rooms, each having separate, dedicated ventilating and/or airconditioning (VAC) systems.

This invention separately provides food processing facilities, systemsand methods that reduce the ability of contamination to migrate from anadulterated location or machine and/or from outside of the facility toan unadulterated location or machine by drawing all initial and make-upair supplied to a particular VAC system from outside the food processingfacility containing the individual food processing rooms.

This invention separately provides food processing facilities, systemsand methods that use a first conveyor system to convey unpackagedlethality-treated food product(s) into a food processing room to befurther processed in that room and a separate packaged food outputconveyor system that conveys food product packaged in that foodprocessing room to a downstream handling system.

This invention separately provides food processing facilities, systemsand methods that provide higher air pressure regions in the foodprocessing rooms and lower air pressure regions around input and outputconveyor systems such that air flows from the food processing room intothe conveyor areas.

This invention separately provides food processing facilities, systemsand methods where each food processing room has a sloped floor leadingto a dedicated floor drain and line that continues uninterruptedly fromthe food processing room to a point where the drain line can be pluggedindependently of any of the other drain lines.

This invention separately provides food processing facilities, systemsand methods for plugging the drain and filling the drain line and thelower portions of the associated food processing room with adisinfectant or the like which sanitizes the plugged portion of thedrain, the room floor and the lower portions of the structures in thefood processing room.

This invention separately provides food processing facilities, systemsand methods in which air is circulated into the food processing rooms ata sufficiently high velocity to dry and maintain dry the floor and anyequipment services within a particular food processing room betweensanitizing cleaning procedures.

This invention separately provides food processing facilities, systemsand methods where the joints between walls, walls and ceiling, and/orwalls and floor are specially designed and treated to inhibit movementof water or moisture between individual floor, ceiling or wall panels,and into or between separate food processing rooms.

This invention separately provides food processing facilities, systemsand methods that use special floor-wall joint structures to inhibitmoisture transfer between food processing rooms and between foodprocessing rooms and food delivery areas, food boxing areas, and otherfood processing areas and from occurring beneath the walls dividing eachseparate food processing room from other food processing rooms and fromcommon areas.

This invention separately provides food processing facilities, systemsand methods that include footwear sanitizing stations within the foodprocessing facility at interfaces between different food processingand/or common areas.

This invention separately provides food processing facilities, systemsand methods for receiving food product(s) to be processed in the foodprocessing facility and for sanitizing the exterior surfaces of the foodproduct(s) to be processed at the food processing facility beforedelivering the food product(s) to be processed to the separate foodprocessing MOMS.

In various exemplary embodiments of food processing facilities, methodsand systems according to this invention, any persons entering secure andsemi-secure areas of the food processing facility must wear specializedfootwear, which must be sanitized upon entering and exiting semi-secureand secure areas of the food processing facility. Persons moving betweenvarious ones of the semi-secure and secure areas of the food processingfacility must also pass through footwear sanitizers as they move betweenthe different sub-portions of the food processing facility. Employeesentering a secure area, where the food product is exposed, must wear aclean “secure area” uniform. All other persons entering the semi-secureareas of the food processing facility must wear designated clothing andare prevented from entering the secure areas of the food processingfacility. In various exemplary embodiments, upon a person exiting thesecure areas to a semi-secure or unsecure area, the current secure areauniform worn by that person must be discarded and a new sanitized securearea uniform must be worn and footwear appropriately sanitized beforere-entering any secure area. Any equipment, such as tools, that are tobe taken into one of the food processing rooms is desirably flushed withalcohol or otherwise sterilized before that equipment can be taken intothat food processing room.

In various exemplary embodiments of food processing facilities, systemsand methods according to this invention, food product(s) to be processedentering even the semi-secure areas of the food processing facility mustbe pre-cooked and/or must have been otherwise subjected to appropriateprotective and lethality treatments to ensure that the food product(s)are essentially free of adulterating pathogens when they enter the foodprocessing facility. In various exemplary embodiments, the foodproduct(s) must be received in casings, other sealing material or thelike, which are also essentially free of adulterating pathogens. Afterbeing received at the food processing facility, and before anyprocessing of the received food product(s), the casing, sealing materialor the like are sanitized and the food product(s) are next removed fromthe casing, sealing material or the like and one or more furtherlethality treatments are applied to kill any pathogens that mightsomehow have reached the surface of the food product(s).

After the one or more lethality treatments, the received food product(s)are transported, for example, by conveyor through a food producedelivery area, to each of the separate food processing rooms for furtherfood processing. In general, the food product(s) delivery areas throughwhich the food product(s) pass between the final lethality treatmentsand the food processing rooms are also treated as secure or sterileregions such that any source of contamination is excluded from suchregions. In various exemplary embodiments, the food product(s) pass fromthe delivery area, which is at a first pressure, through a deliveryopening into a particular food processing room, which is maintained at ahigher air pressure, such that air moves unidirectionally through thedelivery opening in the direction opposite that of the food product(s)as they enter that food processing room.

In various exemplary embodiments of food processing facilities, systemsand methods according to this invention, once in a given food processingroom, the food product(s) is processed and immediately packaged fortransport out of the food processing facility while in that foodprocessing room. The packaged food product(s) is then transported, forexample, by conveyor, out of the higher air pressure food processingroom into a second common area. Because the food processing room is alsoat a higher pressure than this second common area, air constantly movesunidirectionally through the exit opening in the direction of movementof the packaged food product(s). The packaged food product(s) from thevarious food processing rooms are then inspected for package integrity,further packaged, held under refrigerated conditions and prepared fortransport to a customer for sale to the ultimate consumer. Any inspectedpackage which lacks integrity is rerouted for another lethalitytreatment before repackaging in the food processing room from which itcame.

In various exemplary embodiments of food processing facilities, systemsand methods according to this invention, should one of the isolated foodprocessing rooms become contaminated, that room can be shut down andsterilized without affecting the operation of other food processingrooms. Furthermore, because all of the food product processed in thatfood processing room were separately packaged and identified while inthat food processing room, the food product from that food processingroom is inherently distinguishable from the food products processed inthe other food processing rooms, and thus can be separately recalled orotherwise destroyed. If contaminated, that food processing room can thenbe sterilized using a combination of one or both of heat and chemicalsanitizers. In addition, the drain for that room can be separatelyplugged and flushed for sanitizing reasons without affecting theoperation of the drain lines of the other food processing rooms.

In various exemplary embodiments of food processing facilities, systemsand methods according to this invention, when repair or maintenance ofthe machinery in a given food processing room is required, maintenancepersonnel entering that food processing room must also be wearing securearea uniforms and go through the same sanitary procedures as theoperators working in that food processing room. In various exemplaryembodiments, if the maintenance personnel are coming from another foodprocessing room, those maintenance personnel desirably don new, sanitaryfood processing uniforms.

In various exemplary embodiments of food processing facilities, systemsand methods according to this invention, each of the food processingrooms contains all of the supplies and tools necessary to perform commonmaintenance procedures and to repair the food processing equipment dueto common or expected faults. Accordingly, for simple or common repairsor maintenance, the maintenance personnel do not need to carry any toolsor supplies into that food processing room. If more unusual repairs ormaintenance needs to be made, any parts, supplies or tools that must becarried into that food processing room by the maintenance personnel aredesirably first subjected to an alcohol wash or other appropriatecleaning and/or sterilizing procedure before those parts, suppliesand/or tools are carried by the maintenance personnel into that foodprocessing room.

These and other individual features and advantages which may beseparately incorporated in various exemplary embodiments of systems andmethods according to this invention are described in, or are apparentfrom, the following detailed description of various exemplaryembodiments of the systems, methods and facilities for processing foodaccording to this invention.

BRIEF DESCRIPTION OF DRAWINGS

Various exemplary embodiments of the systems, methods and foodprocessing facilities of this invention will be described in detail,with reference to the following figures, wherein:

FIG. 1 is a schematic top plan view of a first exemplary embodiment of afood processing facility and food processing systems according to thisinvention;

FIG. 2 is a schematic top plan view illustrating one exemplaryembodiment of a drain system usable with the first exemplary embodimentof the food processing facility and related systems according to thisinvention shown in FIG. 1;

FIG. 3 is a schematic top plan view of a second exemplary embodiment ofa food processing facility and related systems according to thisinvention;

FIG. 4 is a cross-sectional view of second and third exemplaryembodiments of curb structures according to this invention;

FIGS. 5 and 6 are schematic top and side views, respectively, of a firstexemplary embodiment of a ventilating and air conditioning system for afood processing room according to this invention;

FIGS. 7 and 8 are a flowchart outlining one exemplary embodiment of amethod for processing a food product according to this invention;

FIGS. 9 and 10 are a flowchart outlining one exemplary embodiment of amethod for controlling movement of personnel within a food processingfacility according to this invention; and

FIG. 11 is a flowchart outlining one exemplary embodiment of a methodfor providing heating, ventilation and air conditioning to a given foodprocessing room according to this invention.

DETAILED DESCRIPTION OF DISCLOSED EMBODIMENTS

As developed countries, such as the United States, consume ever largerpercentages of processed food products, the safety of such processedfood products has become of paramount importance. As a result, variousgovernmental agencies in such developed countries have promulgatedvarious rules and regulations which have improved food quality andsafety and have substantially eliminated contamination or adulterationof such processed food products by most common food-born pathogens.

However, this has opened up the possibility of contamination oradulteration by more marginalized food pathogens. That is, the mostcommon food pathogens are those that grow most readily and rapidly onfood products at room temperatures in standard environments, and can becontrolled or lethally treated by refrigeration and heat treatment.However, in the absence of such pathogens controlled or eliminated byconventional refrigeration and heat treatment, other pathogens haveshown the ability to grow and prosper under refrigerated conditions.

For example, Listeria monocytogenes (“LM” or “Listeria”) is one suchbacteria that is better able to tolerate colder temperatures than morecommon bacterial species. As a result, Listeria is able to successfullycolonize and multiply at refrigeration temperatures that control thegrowth of more common bacteria. In fact, Listeria colonies can grow toconcentrations in refrigerated processed food products that can causefatal side affects in humans when such processed food products areconsumed. As a result, current food safety standards generally requirethat contamination or adulteration of processed food products byListeria be, ideally, completely avoided.

The following detailed description of various exemplary embodiments offood processing facilities, systems and methods according to thisinvention are described relative to controlling the risk of Listeriamonocytogenes adulteration of processed meat products. However, itshould be appreciated that the food processing facilities, systems andmethods illustrated by the exemplary embodiments described herein areequally applicable to other types of processed food products, such asdairy products, fruit and vegetable products, and the like. Moreover, itis likely that other bacteria and other pathogenic microorganisms, inaddition to Listeria, such as Salmonella, are or will become of concernin the future. It should be appreciated that the food processingfacilities, systems and methods according to this invention illustratedby the following exemplary embodiments are equally useful in reducingthe ability of other pathogenic microorganisms to adulterate processedfood products, such as meat products, dairy products, fruit and/orvegetable products, or the like. However, for ease of understanding andsimplicity of discussion, the following detailed descriptions willdisclose food processing facilities, systems and methods for reducingcontamination or adulteration of processed meat products with particularreference to Listeria.

FIG. 1 is a schematic top plan view of a first exemplary embodiment of afood processing facility 100 according to this invention that employs“single-line” food processing rooms and clean room-like procedures toboth reduce the ability of Listeria monocytogenes or other pathogens toinitially contaminate a single-line food processing room or other areaof the food processing facility 100 from outside of the food processingfacility 100, and, if a single-line food processing room or other areaof the food processing facility 100 should become contaminated, reducethe likelihood that the contamination will spread to other single-linefood processing rooms or other areas of the food processing facility100. In particular, the food processing facility 100 shown in FIG. 1 isa meat and cheese slicing facility. However, it should be appreciatedthat various ones of the different structures of the food processingfacility 100 described herein can be applied to food processing plantsdesigned for processing other types of food products and other types offood processing operations.

As shown in FIG. 1, previously-processed meat products are received at areceiving area 118 of the food processing facility 100 and stored in afood product storage cooler 110 until such time as a particular portionof the received food product is ready for further processing in the foodprocessing facility 100. It should be appreciated that, in variousexemplary embodiments, to reduce the likelihood that the food product tobe processed in the food processing facility is not contaminated when itis received at the food processing facility 100, only previouslyprocessed food products, such as previously cooked meat products, arereceived and processed by the food processing facility 100. In variousexemplary embodiments, to reduce this risk as much as possible, any rawor untreated food products are denied entry into the food processingfacility 100. In various exemplary embodiments, the received processedmeat product is a relatively long tubular cooked meat product which willbe subsequently sliced at the food processing facility 100. Such longtubular cooked meat products are commonly referred to as “logs”. Invarious exemplary embodiments, these logs 114 have been encased in asealed plastic casing after cooking and prior to arrival at the facility100.

In various exemplary embodiments according to this invention, thereceived food products, such as the encased logs, as received, arestored in specialized stainless steel containers, racks, or any otherappropriate device that can be used to transfer the received foodproduct to the food processing facility. The containers 116 allowdifferent lots of the processed meat product or other received foodproduct to be kept separately from other lots to avoidcross-contamination while the received food products are beingtransported and/or while the received food products are awaiting furtherprocessing. In various exemplary embodiments, the received ready-to-eatfood products to be processed in the food processing facility 100 aretransported to the food processing facility 100 on a “just-in-time”schedule. However, even in this case, it is often necessary totemporarily store the containers 116 in the storage cooler 110. By usingthe containers 116, only limited amounts of the processed food productneed to be exposed when removing the logs 114 from the containers 116for transport into the secure areas of the food processing facility 100.It should be understood that, in various exemplary embodiments,conventional enclosures (not shown) are used between the trailer of thedelivery truck and the doorway to the receiving area 118 of the foodprocessing facility 100 to minimize the possibility of contamination ofthe food product while moving the containers 116 from the trailer to thereceiving area 118 of the food processing facility 100.

The receiving area 118 where the containers 116 of received food productenter the food processing facility 100 and the storage cooler 110 aretwo portions of a semi-secure region 104, which also includes a bufferzone 115, that lies between generally unsecured areas where little or noeffort is made to ensure that food pathogens are not present, and secureareas of the food processing facility 100, where extensive efforts aremade to prevent food pathogens from entering such areas and to inhibitthe spread of food pathogens should any be present in the secure areas.It should be appreciated that the terms “secure” and “semi-secure” referto the efforts to exclude food pathogens and other microorganisms, andnot to efforts directed to preventing theft, unauthorized access,terrorism or the like.

In various exemplary embodiments, when a food log 114 (or any otherprocessed food product) is to be removed from the storage cooler 110 forfurther processing, the container 116 containing that log 114 istypically removed from the storage cooler 110 and placed adjacent to aconveyor 112. The log 114 is removed from its container 116 and placedonto the conveyor 112, which conveys the log 114 into a treatment room120. The treatment room 120 is used to reduce the presence of, andideally completely remove, any bacteria or other pathogenicmicroorganisms, which may have opportunistically colonized the processedfood products, before the processed food product is transported into thefood processing facility 100.

For example, for processed ready-to-eat meat logs 114, as previouslyindicated, the meat logs 114 are typically sealed in plastic casingswhen received from the upstream food processing facility that formed theprocessed meat logs 114. In various exemplary embodiments, theplastic-encased meat logs 114 are transported in the containers 116 fromthe storage cooler 110, removed from the containers 116 and placed ontothe conveyor 112, which conveys the logs 114 through a sanitizing washer111 to remove any pathogens which may be present on the exterior of thecasing, and into the treatment room 120, where the cleansed plasticcasing is removed from around the processed meat log 114 and discarded.The exterior surface of the processed meat log 114 is then subjected toa post-lethality treatment to reduce, and ideally eliminate, anybacteria or other pathogenic microorganisms that may have colonized thesurface of the processed meat log 114.

In various exemplary embodiments, the term “post-lethality treatment”means a treatment that is applied to the processed meat log 114 (orother food product to be processed in the food processing facility 100)after it was subjected to cooking or another upstream lethalitytreatment at the upstream food processing facility before being packagedfor transport to the food processing facility 100. In various exemplaryembodiments of the food processing facility 100, the post-lethalitytreatment applied in the treatment room 120 comprises running the meatlog through a treatment device 122 and/or an infrared tunnel 125 (shownin the area 130) that heats the entire surface of the processed meat log114 to a sufficiently high temperature that any pathogenic bacteria orother microorganisms which may be present on the surface of the meat log114 are expected to be killed. The treatment device 122 can be a hotliquid bath, such as a hot oil bath or hot water bath, or a steamtreatment device, or another appropriate device that obtains a productsurface temperature that results in a 2 log reduction in the pathogen.In another exemplary embodiment, the meat log may be run through aconventional chemical sanitizer (not shown) employing, for example, asanitizing solution comprising chlorine or peracedic acid. The treatedmeat log 114 (or other processed food product) is then transported on aconveyor 124 from the treatment device 122 and/or 125 that is within thetreatment room 120 into a delivery area 130. In various exemplaryembodiments, the conveyor 124 may deliver the treated meat log 114 to acruster 128, such as a Vertical Rapid Cruster manufactured by UnithermFood Systems of Bristow, Okla., which creates a uniform frozen crust inthe surface of the meat log 114 to improve the sliceability of the meatlog 114. From the cruster 128, the conveyor 124 delivers the crustedmeat log 114 to a distribution conveyor 132 located in the delivery area130. The distribution conveyor 132 is used to convey a particular meatlog 114 or other treated food product to a desired one of a plurality ofsingle-line food processing rooms 140.

It should be appreciated that, in various exemplary embodiments, thetreatment room 120 is another portion of the semi-secure region 104. Insuch exemplary embodiments, while the food product is unsealed andexposed in the treatment room 120, because of the treatment applied inthe treatment room 120, the treatment room 120 does not need to be partof the secure area 106. However, if desired, the treatment room 120 canbe made part of the secure area 106. It should also be appreciated that,in various exemplary embodiments, the treatment room 120 is equippedwith an exhaust system 121 for maintaining a slightly negativeatmospheric pressure in the treatment room 120. Thus, air will be pulledout of the delivery area 130 into the treatment room 120, and then,together with any fumes from the fryer 122, is exhausted out of thefacility 100 to the outdoors by the exhaust system.

Alternatively, one or more infrared tunnels 125 may be located in thedelivery area 130, as shown in FIG. 1. Accordingly, in various otherexemplary embodiments, while a lethality treatment is applied to aparticular log 114 or other processed food product, that log 114 orother processed food product does not go through the treatment room 120.In this case, a dedicated lethality treatment or device may be providedfor one or more sets of one or more such food processing rooms 140 thatprocess such a log or other processed food product. For example, if thetreatment applied in the treatment room 120 is applied using a heatedoil bath, but the customer does not want the processed food product togo through such a process, or the food product cannot withstand such atreatment, that food product will skip the treatment room 120. In thiscase, the food product can be removed from its container 116 and theoutside of the casing sanitized. The sanitized food product is thendelivered to the delivery area 130, the casing removed, and the uncasedfood product 114 transported to the appropriate food processing room140. At some point between having the casing removed and beingtransported into the appropriate food processing room 140, the lethalitytreatment, such as passing through an infrared tunnel 125 shown in FIG.1, or the like, is applied to the uncased food product 114 while in thedelivery area.

The various single-line food processing rooms 140 are the only locationswithin the food processing facility 100 where the food product to beprocessed, such as the meat logs 114, is actually processed, other thanreceiving lethality treatments, such as those described above. It shouldbe appreciated that only a single line of food processing devices may beprovided in each of the various “single-line” food processing rooms 140.This remains the case even if the single line of food processing devicesin a given food processing room 140 is divided into two separate foodprocessing paths or sets, as there is a single food product inlet fromthe food delivery 130 to a single-line food processing room 140 and asingle outlet from a single-line food processing room 140 to a packagedfood receiving area 150. The food processing devices in that single-linefood processing room 140 are independent of the food processing devicesin any other single-line food processing room. In any case, the productpackaged in any such single-line food processing room 140 will receivean unique identity code, printed on the package, which will enable theoperators to trace every package produced in the food processingfacility 100 back to the individual food processing room 140 in which itwas processed and packaged.

In various exemplary embodiments, each set or line of devices in asingle-line food processing room 140 includes two or moreserially-connected food processing elements. For example, in variousexemplary embodiments of the food processing facility 100, each of thesingle-line food processing rooms 140 is a slicing room where the meatlogs 114 are converted into sliced meat product. In some exemplaryembodiments of such slicing rooms, the output of an upstream foodprocessing device is directed to a single downstream food processingdevice and only one such line is present in any given single-line foodprocessing room 140. For slicing operations, a single-line foodprocessing room 140 will typically include a slicing machine 142 and apackaging machine 146.

It should also be appreciated that, in various exemplary embodimentsaccording to this invention, any food product leaving a single-line foodprocessing room 140 will be packaged before it leaves that single-linefood processing room 140. It should be appreciated that “packaged”generally encompasses providing a sealed barrier between the processedfood product and its ambient environment, such that any pathogens in theambient environments that the processed food product experiences afterleaving the single-line food processing room 140 and until the openingof the package, either by the end consumer or within another downstreamfood processing facility, are unable to penetrate the barrier andcontaminate or adulterate the processed food product.

As shown in FIG. 1, a transfer conveyor 134 receives the meat logs 114or other processed food product from the distribution conveyor 132 andconveys the meat logs 114 or other processed food product from thedelivery area 130, through a passage or opening in a wall separatingthat single-line food processing room 140 from the delivery area 130,and into the interior of the single-line food processing room 140. Itshould be appreciated that the processed food product can go directlyfrom the treatment room 120 to one of the single-line food processingrooms 140. In various other exemplary embodiments, the treated foodproduct is chilled, for example, by using the cruster 128 describedabove, before being delivered to the single-line food processing room140. Using the cruster 128 both reduces the surface temperature of thelog 114, and arrests any bacterial activity that could otherwise occuron the surface of that log 114 after passing through the oil bath orinfrared tunnel, and also beneficially makes the log 114 easier toslice. The chilled log 114 or other food product is then transported tothe appropriate food processing room 140 as described above.

It should be appreciated that, in various exemplary embodiments, thepassage or opening for the conveyor 134 through the wall separating thesingle-line food processing room 140 from the delivery area 130 isdesirably sized on the order of the meat log 114 or other processed foodproduct being conveyed by the transfer conveyor 134. It should also beappreciated that the single-line food processing room 140 is desirablykept at a higher internal pressure and a colder temperature than thepressure and temperature within the delivery area 130. As a result,there is a positive or increasing pressure gradient along the directionof travel of the transfer conveyor 134 such that there is anunidirectional air flow out of the single-line food processing room 140into the delivery area 130. This ensures that any pathogens which may bepresent in the atmosphere in the delivery area 130, however unlikely,cannot travel by aerosol action or air flow from the delivery area 130into a particular single-line food processing room 140.

Once in a given single-line food processing room 140, each meat log 114or other processed food product received from the delivery area 130passes generally (i.e., more or less) serially through the various foodprocessing and/or packaging machines that form the single foodprocessing line contained within that single-line food processing room140. As shown in FIG. 1, the meat log 114 or other processed foodproduct transported by the transfer conveyor 134 travels to a feederstation 142, where the meat log 114 or other processed food product isfed to a slicing machine 143 and sliced into a plurality of separateslices of a desired thickness. A number of slices are gathered into aportion and the plurality of slices of the sliced food product forming aportion are then conveyed together by a second transfer conveyor 144 to,and packaged by, a packaging machine 146. In various exemplaryembodiments, the sliced meat or other processed food product is packagedinto thermoformed plastic cavities, which are then flushed with a gas asa plastic sheet is heat sealed to the cavity rim to form a hermetic orother impervious seal. In contrast, in various other exemplaryembodiments, the sliced meat or other processed food product portion isvacuum packaged and sealed while in the single-line food processing room140.

It should be appreciated that, in various other exemplary embodiments,different types of food processing equipment will be contained withinthe single-line food processing room 140. In some exemplary embodiments,regardless of the types and numbers of food processing devices containedwithin the single-line food processing room 140, the various foodprocessing devices will be organized such that a single line or seriesof food processing devices, through which all of the received meat logs114 or other processed food products pass, is formed. That is, in suchexemplary embodiments, the various food processing devices containedwithin the single-line food processing room 140 are not organized intotwo separate, effectively parallel lines or the like. By having only asingle line of series-connected food processing devices in eachsingle-line food processing room 140, each single-line food processingroom 140 becomes essentially a separate food processing facility.

Thus, if any one of the food processing devices in a single one of thesingle-line food processing rooms 140 becomes contaminated, only theprocessed food product which passed through that single-line foodprocessing room 140 could be contaminated. Should a particular lot ofprocessed food product which passed through that single-line foodprocessing room 140 need to be recalled and/or destroyed beforeshipping, that processed food product lot can be dealt with in theknowledge that none of the other processed food products produced by theother single-line food processing rooms 140 in the food processingfacility 100 need to be recalled the contamination present only withinthat first single-line food processing room 140. Likewise, should aparticular device within the single-line food processing room 140 becomecontaminated, there will be a concern that all of the processed foodproduct passing through that single-line food processing room 140 duringthe contamination period may have come into contact with that particularcontaminated food processing device and thus, may need to be recalledand/or destroyed or otherwise rehabilitated.

However, it should be appreciated that, in less rigorous exemplaryembodiments, a particular “single-line” food processing room 140 couldcontain more than one of a particular type of food processing equipmentthat is fed by a set of one or more input conveyor(s) and discharged toa set of one or more output conveyor(s). However, in this case, whilethe risk of cross-contamination between food processing lines indifferent food processing rooms 140 has been reduced, the ability ofListeria or other pathogenic microorganisms to cross contaminateparallel machines within a single-line food processing room 140 is notinhibited.

The packaged food product is then output from the packaging device 146on to a third transfer conveyor 148. The third transfer conveyor 148transports the packaged food product into the receiving area 150. Inparticular, the third transfer conveyor 148 passes through a passage oropening in a wall that separates the single-line food processing room140 containing that transfer conveyor 148 from the receiving area 150.In various exemplary embodiments, the passage or opening is desirablysized on the order of the size of the packaged food product beingtransferred out of that single-line food processing room 140.

In various exemplary embodiments, as the packaged food product entersthe receiving area 150 on the third conveyor 148, the packaged foodproduct is inspected. If the inspection reveals that a particularpackaged food product needs to be re-packaged, that packaged foodproduct is placed on a return conveyor (not shown) that conveys thatpackaged food product back into the food processing room 140 that itcame from. The returned packaged food product's package is sanitizedbefore or as it enters that single-line food processing room 140. Oncein that food processing room 140, the returned food product package isopened and disposed of and the returned food product is placed into anew package and resealed.

In contrast, in some exemplary embodiments, the third transfer conveyor148 deposits the packaged processed food product from that single-linefood processing room 140 onto a collection conveyor 152 that collectsvarious processed and packaged food products from the varioussingle-line food processing rooms 140. Once on the collection conveyor152, the packaged processed food product can be inspected, boxed,collected and/or palletized for shipping to a finished product cooler, awarehouse, or the ultimate consumer.

It should also be appreciated that, like the delivery area 130, thereceiving area 150 is at a lower atmospheric pressure and temperaturethan the single-line food processing rooms 140, although the receivingarea 150 does not need to be at either the same pressure or the sametemperature as the delivery area 130. As a result, there is adecreasing, or negative, pressure gradient along the direction of travelof the third transfer conveyor 148 as it passes through the opening inthe wall separating the single-line food processing room 140 from thereceiving area 150. As a result, there is a unidirectional air flow fromthe single-line food processing rooms 140 into the receiving area 150,effectively preventing the migration of any pathogens present in thereceiving area 150 into the single-line food processing rooms 140through the limited openings in the walls separating the single-linefood processing rooms 140 from the receiving area 150. Likewise, therewill be a similar unidirectional air flow from the single-line foodprocessing rooms 140 to the receiving area 150 surrounding the returnconveyors (not shown) and the packages being returned to the single-linefood processing rooms 140 for repackaging.

To further reduce the ability of Listeria and other pathogenicmicroorganisms from migrating from place to place within the foodprocessing facility 100, the food processing facility 100 is dividedinto the first region 102, the second region 104 and the third region106. In general, the first region 102, which corresponds to theunsecured area, includes such facilities as locker rooms where thepersonnel employed in the food processing facility 100 can change theirclothes, lunch and/or break rooms where the personnel can take theirbreaks and/or eat breakfast, lunch or dinner, restrooms, offices for themanagement personnel for the food processing facility 100 and the like.The first region 102 can also include conference and meeting rooms,visitor reception areas and the like. Because these areas are in thefirst region 102, rather than in the second region 104, it is likelythat the personnel employed by the food processing facility 100 willmake multiple trips between the first region 102 and the second or thirdregions 104 or 106 during the typical work shift. The second region 104,which corresponds to the semi-secure area, includes a clean uniformstorage 117 in the buffer zone 115, the storage cooler 110, thereceiving area 118, the treatment room 120, and the receiving area 150.The third region 106, which corresponds to the secure areas, includesthe delivery area 130 and the various single-line food processing rooms140.

In general, movement within the first region 102 and access to the firstregion 102 from outside the food processing facility 100 by authorizedpersonnel is generally not restricted. Accordingly, employees and otherauthorized personnel can freely enter the first region 102 from thesecond region 104 and from outside the food processing facility 100.Thus, the first region 102 can be referred to as an “unsecure area”. Incontrast, access to the various rooms and areas forming the secondregion 104 and movement between those regions and the first region 102is strictly controlled. In particular, movement between the first region102 and the second region 104 requires passing through a sanitizingstation 160, such as the sanitizing station 161 located between thefirst area 102 and the buffer zone 115. In addition, in variousexemplary embodiments, movement from the first region 102 into thesecond region 104 requires that special clothing or uniforms be donnedprior to or immediately after passing through the sanitizing station161. Similarly, moving from the second region 104 into the first region102 requires passing through the sanitizing station 161 and removal ofthe special clothing or uniform.

In various exemplary embodiments, the required clothing includes rubberboots or other appropriate footwear that is generally impervious toliquids and from which Listeria and other pathogenic microorganisms canbe relatively easily removed. In such exemplary embodiments, thesanitizing station 161 includes footwear scrubbing and/or sanitizingdevices that use both mechanical devices and chemical applications toremove and/or kill any bacteria that may be present on the rubber boots.When personnel pass between the first and second regions 102 and 104,they are required to pass through the sanitizing station 161 to ensurethat no Listeria or other pathogenic microorganisms that may be presenton the employees' footwear survives the sanitizing station, such thatsuch microorganisms are not transported between the first and secondregions 102 and 104.

In various other embodiments, in addition to or instead of the rubberfootwear, the specialized clothing can include head coverings, smocksand other over-clothing, and even can include specialized cleanroom-type sanitized suits or uniforms. Additionally, in variousexemplary embodiments, personnel leaving the second region 104 andentering the first region 102, before or after passing through thesanitizing station 161, are required to remove the specialized clothingand recycle it for sanitizing.

Because reasonably strict procedures, including that cooked-only foodproduct be stored and processed in the second region 104, the type offood processing not permitted in the second region 104, and the movementof food processing personnel between the first region 102 and the secondregion 104, are designed to reduce the likelihood that Listeria or otherpathogenic microorganisms are able to enter or migrate into the region104, the region 104 can be referred to as a semi-secure area.Additionally, in various exemplary embodiments, in addition tocontrolling how the food processing personnel move between the firstregion 102 and the second region 104, the types of personnel that arepermitted to move between the first region 102 and the second region 104can also be controlled. In various exemplary embodiments, access to thesecond region 104 can be limited to food processing personnel andvisitors having designated certifications, such as having completed foodsafety specialist training and certification.

Once in the second region 104, access to the delivery area 130, thereceiving area 150, and the single-line food processing rooms 140 can befurther controlled by requiring food processing personnel to passthrough further sanitizing stations 160 between the second region 104and the delivery area 130, the receiving area 150 and the single-linefood processing rooms 140. Thus, in such exemplary embodiments, the foodprocessing personnel pass through additional sanitizing stations 160 toenter the delivery area 130, the single-line food processing rooms 140,or the receiving room 150 from the buffer zone 115, and when passingback into the buffer zone 115 from the single-line food processing rooms140, the distribution area 130, or the receiving area 150.

In various exemplary embodiments, while access to the buffer zone 115may be permitted, access to the third region 106, i.e., at least thedelivery area 130 and the single-line food processing rooms 140, can belimited to food processing personnel having completed food safetyspecialist training and certification and having specific duties withinsuch areas. Furthermore, in various exemplary embodiments, access to thesingle-line food processing rooms 140 is further limited only tooperators of the machines forming the single-line food processing systemin the single-line food processing room 140, to supervisors and qualitycontrol/assurance personnel, and to maintenance personnel who requireentry into a particular single-line food processing room 140 in order tomaintain and/or repair the equipment in that single-line food processingroom 140. In various exemplary embodiments, any food processingpersonnel entering such a single-line food processing room 140 must weara clean room-style protective suit or other appropriate full-bodycovering, in addition to the prescribed footwear. Similarly, in variousexemplary embodiments, any food processing personnel entering thedelivery area 130 are also required to wear such a clean room-styleprotective suit or other appropriate full-body covering. In variousexemplary embodiments, if a food processing employee moves from thethird region 106 back out into any portion of the second region 104,that person must remove the protective suit or other full body coveringand don a new such protective suit or full-body covering beforere-entering the third region 106.

Thus, the likelihood is reduced that any Listeria or other pathogenicmicroorganisms that have been able to migrate into the second or thirdregions 104 or 106 will be able to migrate further into the third region106, i.e., into the delivery area 130, or even further into thesingle-line food processing rooms 140. Likewise, the likelihood that anyListeria or other pathogenic microorganisms which may be present in aparticular single-line food processing room 140 will migrate out of thatsingle-line food processing room 140 into either the other areas of thesecond region 104 or another single-line food processing room 140 isreduced. Because of the additional controls on movement of personnelbetween the third region 106, i.e., the single-line food processingrooms 140 and the delivery area 130, and the other portions of thesecond region 104, the delivery area 130 and the single-line foodprocessing rooms 140 can also be referred to as the “secure areas”.

FIG. 2 illustrates a first exemplary embodiment of a drain system usablein the food processing facility 100 according to this invention.Conventional drains are a potential source of environmentalcontamination. This drain system forms another aspect of the foodprocessing facility 100 that is usable to reduce the likelihood thatListeria or other pathogenic microorganisms will migrate from the otherportions of the third region 106 or the second region 104 into thesingle-line food processing rooms 140, or vice versa, or betweenindividual single-line food processing rooms 140. As shown in FIG. 2,each single-line food processing room 140 has its own dedicated drainline 180-187. As shown in FIG. 2, each drain line 180-187 extendsdirectly from a particular single-line food processing room 140 to oneof a number of collection manholes or catch basins 170, such as themanholes or catch basins 171, 172, and 173.

In particular, as shown in FIG. 2, the various drain lines 180-187 donot intersect each other prior to reaching the particular catch basin170 to which they are connected. Additionally, the outlet of each of thedrain lines 180-187 connects to and preferably discharges by gravityinto the corresponding catch basis 170 at a location that is spacedapart from the outlets of the other drains 180-187 bothcircumferentially, as can be seen in FIG. 2, and/or axially. That is,the outlet for each drain 180-187 into the corresponding catch basin 170is spaced apart from the other outlets both along the circumference ofthe catch basin 170 and along the axis of the catch basin 170 thatextends into and out of the drawing of FIG. 2. Accordingly, any wastematerials flushed down a particular one of the drains 180-187 from aparticular single-line food processing room 140 into the correspondingcatch basin 170 generally will not splash into, be directed into, orotherwise contaminate any of the other ones of the drains 180-187 thatare connected to that catch basin 170. While FIG. 2 shows only foodprocessing room drains 180-187, it should be understood that thefacility 100 will have as many such drains as there are such single-linefood processing rooms 140.

Furthermore, the common drain lines 190, such as the drain lines 191 and192, which are designed to receive waste materials from, for example,the distribution room 130 and/or the receiving room 150, respectively,are also connected to the catch basins 170 at locations that are spacedapart from the drain lines 180-187 both circumferentially and/oraxially, so that waste from the various single-line food processingrooms 140 does not contaminate the drain lines 190 or vice versa. Invarious exemplary embodiments, the drain lines 180-187 are designed withminimum bends or elbows, such that there are minimal locations in thedrain lines 180-189 where waste material can collect within those drainlines 180-187.

In various exemplary embodiments, each of the drain lines 180-187 can befitted with an end cap, damper or valve 188 or other appropriate devicethat allows that drain line 180-187 to be sealed, such that it can bebackfilled for its entire length from the corresponding single-line foodprocessing room 140 with a cleaning and/or sanitizing agent or the like.In various exemplary embodiments, this would allow that drain line180-187, if it were to become contaminated with Listeria or otherpathogenic microorganisms, to be cleaned and/or sterilized to removesuch contamination. In various exemplary embodiments, such caps, valvesor other appropriate structures are located at the outlet ends of thedrain lines 180-187 at the catch basins 170. In various exemplaryembodiments, the catch basins 170 are connected to a waste disposalsystem, such as a sewer system, a waste water treatment system, or thelike. In various exemplary embodiments, the catch basins 170 are locatedoutside of the walls of the food processing facility 100.

In various exemplary embodiments, the floors of the single-line foodprocessing rooms 140 are sloped toward the drain fixtures 194 at theupper ends of the drain lines 180-187, such that any liquids, includingcleaning and flushing liquids which may drop or be directed onto thesloped floors, are directed into the drain fixtures 194 and the drainlines 180-187, regardless of where in the single-line food processingroom 140 the liquid may contact the floor. In various exemplaryembodiments, the drain fixtures 194 may be constructed of anti-microbialstainless steel, such as are supplied by Unitherm Food Systems ofBristow, Okla.

FIG. 3 illustrates a second exemplary embodiment of a food processingfacility 200 according to this invention. It should be appreciated thatthe structures shown in FIG. 3 generally correspond to similarstructures shown in FIG. 1 and/or FIG. 2, including door openings anddoors between the various rooms and areas as shown in FIGS. 1 and 2, andotherwise as may be necessary or convenient. FIG. 3 additionally shows anumber of exemplary curb structures used within the storage cooler 210,the treatment room 220, the delivery area 230, the various single-linefood processing rooms 240, the receiving area 250 and the other regionswhich form the various portions of the second region 104. These curbsare located at the base of the walls of the various portions of the foodprocessing facility 200 used to divide the space within the secondregion 104 into the various rooms discussed above. These curbs mayinclude three different types of curbs, which have increasing abilitiesto slow down or prevent the migration of Listeria or other pathogenicmicroorganisms along or under the walls within the regions 104 and 106.

As shown in FIG. 3, these curbs include a first type of curb 202, whichis used to line the interior surfaces of walls of those spaces where theprocessed food product that is processed within the food processingfacility 200 is not expected to be present. This first type of curb 202can also be used to line those walls where the processed food product ispresent in only a packaged state. Such regions include hallway areas262, maintenance areas 264, dry supply storage area 260, the receivingarea 250, a shipping dock area 270 and the like.

The second type of curb 204 is used to line those walls where it islikely that the processed food product to be processed in the foodprocessing facility 200 will be present, either in a sealed casing or inan unpackaged state but is not being processed. Such regions include thestorage cooler area 210, the buffer zone 215, the treatment room 220,the delivery area 230 and adjacent areas. A third type of curb 206 isused to line the interior walls of the single-line food processing rooms240.

In general, the first type of curb 202 provides relatively lesserprotection against the migration of Listeria and other pathogenicmicroorganisms. The second type of curb 204 provides an intermediatelevel of protection against migration of Listeria and other pathogenicmicroorganisms. The third type of curb 206 provides relatively greaterprotection against the migration of Listeria and other pathogenicmicroorganisms. In general, the curbs 202-206 protect against migrationof such pathogenic microorganisms along and under the walls separatingthe various spaces within the regions 104 and 106 of the food processingfacility 200. In particular, the curbs 202-206 generally prevent waterand other liquids from moving from the enclosed spaces within theregions 104 and 106 to spaces under the walls, either along the walls orto the other sides of the walls, because Listeria and other pathogenicmicroorganisms can be carried by movements of water and other liquidsunder the walls and into other spaces within the regions 104 and 106 ofthe food processing facility 200 unless measures are taken to preventsuch intrusions and movements.

FIG. 3 also shows one exemplary embodiment of a cooling and aircirculation system for the storage cooler 210, the delivery area 230,the receiving area 250, the shipping dock area 270 and the finishedproduct cooler 280, which includes a plurality of evaporator cooler fans196 mounted in the upper portions of the identified areas. Theevaporator coolers may be positioned parallel to one or more walls of anenclosed space, as shown in the storage cooler 210, the shipping dockarea 270 and the finished product cooler 280, or perpendicular to a wallas shown in back-to-back relation in the elongated spaces of thedelivery area 230 and the receiving area 250, or in any other positionwhich will result in a vigorous circulation of cold air sufficient toprovide constant air movement over surfaces of and/or within theidentified areas and their contents to prevent the condensation oraccumulation of moisture on any such surfaces. The maintenance of drysurfaces within the facility 200 by the circulation of cold air minimizethe opportunities for Listeria or other pathogens to colonize on, andsubsequentially spread from such surfaces within such areas to elsewherewithin the facility 200.

FIG. 4 shows one exemplary embodiment of a wall and floor structure 300and various exemplary embodiments of curb structures 400 and 500 usablein food processing facilities 100 or 200 according to this invention. Asshown in FIG. 4, the wall and floor structure 300 comprises a floor 310against or into which a wall 340 is set. In general, the floor 310 isformed of concrete or other hard and generally impervious substance andmay be coated with a lithium-based sealant or other appropriateprotective coating. In various exemplary embodiments, the walls 340, aswell as the ceilings, are constructed of 4″ thick freezer panels 344with urethane foam insulation or the like having an insulating value ofR43.5. Typically, all joints between wall and ceiling panels 340 aredovetailed to provide foam-to-foam interfaces and are caulked to preventany movement of water between or along the panels. The walls 340 mayinclude galvanized steel skins 342 placed on both sides of the foampanels 344. In various exemplary embodiments, water-impervious polymercoatings are formed over the steel skins 342.

It should be appreciated that, in various exemplary embodiments, thecurbs 202 are formed of concrete as shown in FIG. 4 coated similarly tothe floor 310. In contrast, in various exemplary embodiments, the curbs204 and 206 are keyed stainless steel curbs such as that shown in FIG.4. In various exemplary embodiments, the curbs 206 use anti-microbialstainless steel curbs manufactured by Unitherm Food Systems. The curbs204 are standard stainless steel.

As shown in FIG. 4, a simple concrete curb 400 includes a concrete mass420 that contains reinforcing iron bars 410. The iron rebar 410 alsoattaches the concrete curb 400 to the floor 310. Caulking or othersealants are provided at the joints between the concrete curb 400 andthe floor 310, and the concrete 400 and the galvanized steel skin 342 ona wall 340.

As further shown in FIG. 4, a second type of curb 500 includes a groove510 cut into the floor 310, as well as reinforcing iron bars 520 thatextend into the floor 310. A concrete mass 530 extends around thereinforcing iron rebar 520. A stainless steel cover 540 extends aroundthe concrete mass 530 and into the groove 510. The top of the stainlesssteel curb 540 is connected to the stainless steel skin of the wall 340.An epoxy or polyurethane or the like seal 550 is placed in and/or aroundthe groove 510 to seal the stainless steel curb 540 into the groove 510to form an impervious barrier to liquids that may be present on the wall340 and/or the floor 310. It should be appreciated that the curbstructure 500 is particularly useful as the curbs 204 and 206 describedabove. Other curb designs which provide a liquid impervious barrierbetween the floor and the walls under expected conditions, and whichalso provide physical protection to the bases of the walls to reducephysical damage to the walls from impacts from lift trucks, pallets,equipment or the like, and/or which further inhibit the presence orgrowth of microorganisms are also acceptable for the curbs 202, 204 and206.

FIGS. 5 and 6 are top and side plan views of the ventilating and airconditioning (VAC) system for each of the plurality of single-line foodprocessing rooms 140 and 240 described above. That is, in variousexemplary embodiments, each of the single-line food processing rooms 140and 240 has its own separate VAC system, for which FIGS. 5 and 6illustrate one exemplary embodiment. Each separate VAC system 600 ismounted on the outer surface of the ceiling 209 for the correspondingsingle-line food processing room 140 to which that VAC system 600 isconnected.

As shown in FIGS. 5 and 6, each separate VAC system 600 includes an airinlet 610 in which a high efficiency particulate filter 612, such as ahigh-efficiency particulate air (HEPA) filter, is fitted. The VAC system600 also includes a “doghouse” 620 in which a ventilation and airconditioning unit 624 is mounted. The air inlet 610 connects thecorresponding single-line food processing room 140 or 240 to a space 650above the single-line food processing rooms 140 or 240, while an airinlet 622 connects that single-line food processing room 140 or 240 tothe interior of the doghouse 620. Accordingly, the ventilation and airconditioning unit 624 draws air from the single-line food processingroom 140 or 240 through the inlet 622, possibly conditions the withdrawnair, and returns the withdrawn air to that single-line food processingroom 140 or 240 through a duct 630 and a return inlet 632.

It should be appreciated that all initial and make-up air that issupplied to the separate VAC systems 600 and has been drawn from outsidethe food processing facility 100 or 200 first passes through an outsideair intake 670, as shown in FIG. 1, and into the space 650 above thesingle-line food processing rooms 140 or 240. In various exemplaryembodiments, the outside air intake 670 also includes a HEPA filter 672or the like. Because each inlet 610 also includes an intake HEPA filter612, all air drawn from outside the food processing facility 100 or 200passes through two HEPA filters or the like before entering into theindividual single-line food processing rooms 140 or 240.

The VAC system 600 for this particular single-line food processing room140 or 240 circulates the air into that single-line food processing room140 or 240 through the duct or air plenum 630 at near freezing-leveltemperatures and relatively high speeds to create a positive airpressure within that single-line food processing room 140 or 240. Thatis, a pressure greater than ambient atmospheric pressure is created ineach single-line food processing room 140 or 240 by the VAC system 600.Accordingly, no ambient air will be able to flow from the rest of thefood processing facility 100 or 200 into any of the single-line foodprocessing rooms 140 or 240. Rather, during food processing operations,room air will flow out of each of the single-line food processing rooms140 or 240 through the openings through which the incoming and outgoingtransport conveyors pass between the delivery area 130 or 230 and thereceiving area 150 or 250.

If any air needs to be exhausted from the single-line food processingroom 140 or 240, such as after a cleaning operation, an air outlet 642in the ceiling 209 allows air to pass from the single-line foodprocessing room 140 or 240 into an exhaust duct 640, controlled by adamper and control 644, which guides exhaust air through a roof 660 ofthe facility 100 or 200 and thus entirely out of the food processingfacility 100 or 200, while directing that exhaust air away from the airinlet 670. In various exemplary embodiments, all exhaust air from anyportion of the facilities is exhausted entirely out of the facilities tothe outdoors.

It should be appreciated that, in various exemplary embodiments, the airis introduced into the particular single-line food processing rooms 140or 240 by the VAC system 600 at a substantial velocity of, for example,22 miles per hour, to quickly dry and maintain dry the floor and anyequipment surfaces to avoid wet surfaces where Listeria or otherpathogenic microorganisms could grow or prosper. In various exemplaryexamples, this air is exhausted through the exhaust duct 640 to theoutside during and after the introduction of water or other liquids intothe corresponding single-line food processing room 140 or 240, such asby daily cleaning, backfilling of a room drain and floor area with adisinfectant, or the like.

It should also be appreciated that, in various exemplary embodiments,any piping of any kind entering the single-line food processing rooms140 or 240, or any other areas of the plant, is preferentially orientingvertically down from the utility space above and through the ceiling209, such that horizontal pipe runs extending within the single-linefood processing rooms 140 or 240 and other plant areas are eliminated orminimized, as horizontal pipe can provide surfaces where moisture cancondense and collect.

It should also be appreciated that, in various exemplary embodiments, aselected single-line food processing room 140 or 240 and all of thecontents of that single-line food processing room 140 or 240, may beheated to a temperature and for a time that should be sufficient to belethal to any Listeria bacteria or other pathogenic microorganisms thatmight be found on, or suspected to be present on, the devices formingthe single-line food processing system, including the food processingdevices, the packaging equipment or any other locations within thatsingle-line food processing room 140 or 240. Thus, in such exemplaryembodiments, it would not be necessary to completely remove theequipment or physically reach every pathogen on the equipment in thatsingle-line food processing room 140 or 240 in order to sanitize theequipment in that single-line food processing room 140 or 240.

It should be appreciated that, in such exemplary embodiments, the walls208 and the ceiling 209 used to separate each of the single-line foodprocessing rooms 140 or 240 from each other and from the areas withinthe region 104 of the food processing plant 200 should be designed to beable to withstand experiencing such elevated temperatures forsufficiently long periods of time to allow the food processing equipmentin that single-line food processing room 140 or 240 to be heatsterilized. It should also be appreciated that it may be desirable,depending on the construction of the walls 208 and/or the ceiling 209,to warm up one or more adjacent ones of the normally refrigeratedsingle-line food processing rooms surrounding the single-line foodprocessing room 140 or 240 to be sterilized, or to heat one or moreadjacent single-line food processing rooms 140 or 240 having acommon-pour floor section with the single-line food processing room 140or 240 to be sterilized, to avoid creating too large a temperaturedifferential between the single-line food processing room 140 or 240being sterilized and the surrounding single-line food processing rooms140 or 240. It should also be appreciated that the temperature of theroom or rooms to be heated could be raised and lowered slowly betweennormal operating temperature and heat sterilization temperature to avoidstructural damage.

FIGS. 7 and 8 are a flowchart outlining one exemplary embodiment of amethod for handling processed food product(s) within a food processingfacility according to this invention. As shown in FIGS. 7 and 8, themethod begins in step S100 and continues to step S105, where aninitially-processed food product is received and possibly stored in adesignated area of the food processing facility. As outlined above, invarious exemplary embodiments, this designated area can be a short-termstorage cooler or the like. Next, in step S110, a portion of thereceived food product is selected for processing by the food processingfacility. In various exemplary embodiments, as outlined above, theselected portion can be a meat log or the like. Next, in step S115, theselected portion of the food product is transferred from the designedarea to a treatment area or the like. Operation then continues to stepS120.

In step S120, at least one post-processing lethality treatment isapplied to the selected portion of the food product. As outlined above,this is done to reduce the likelihood that an opportunistic adulterant,such as Listeria or other adulterating microorganism, has colonized thesurface of the selected portion of the food product to be processed.Next, in step S125, the selected portion of the food product istransferred from the treatment area or the like to a near-sterile foodproduct delivery area. In general, the selected portion is transferredusing any desirable appropriate devices which reduce the likelihood thatthe surface of the food product will be recolonized with Listeria orother pathogenic microorganisms as it is transferred from the treatmentarea or the like through the food product delivery area to theparticular single-line food processing room 140 in which that foodproduct will be further processed. It should be appreciated that stepsS120 and S125 can be reversed, in that the food product can be treatedafter it is in the delivery area rather than before it enters thedelivery area. Then, in step S130, the treated selected portion of thefood product is transferred from the food product delivery area to asingle-line food processing room through an opening in the wallseparating the food product delivery area from the single-line foodprocessing room. It should be appreciated that, in various exemplaryembodiments, a positive pressure gradient, as outlined above, is appliedto this opening to create a pressure differential across that opening.By forming a positive pressure gradient from the interior of thesingle-line food processing room to the food product delivery area, airmoves through the opening toward the food product delivery area from thesingle-line food processing room. This tends to prevent air-bornemicroorganisms, such as Listeria, from entering the single-line foodprocessing room. Operation then continues to step S135.

In step S135, the received portion of the food product is processed inthe single-line food processing room using a set of one or more foodprocessing devices. Then, in step S140, the processed food product istransferred within the single-line food processing room from the one ormore food processing devices to one or more food packaging devices.Next, in step S145, the processed food product is packaged within thesingle-line food processing room. Operation then continues to step S150.

In step S150, the packaged food product is transferred from thesingle-line food processing room to a receiving area through an openingin the wall separating the single-line food processing room from thereceiving area. In various exemplary embodiments, a pressure gradient iscreated across that opening from the single-line food processing room tothe receiving area to generate a unidirectional flow of air from thesingle-line food processing from into the receiving area. Next, in stepS155, the packages of packaged food product are inspected for leakage orother faults with the packaging such that Listeria or other pathogenicmicroorganisms could migrate into that packaging. Next, in step S160,any leaking or defective food product packages are returned to thesingle-line food processing room 140 from which they came forre-sterilization and repackaging in the single-line food processingroom, are discarded or otherwise appropriately dealt with. Operationthen continues to step S165.

In step S165, a determination is made whether the food product waspackaged on a Friday or other designated day. It should be appreciatedthat Friday is used to allow the food product packaged on that day to beextensively inspected, sampled and tested for the presence of pathogens,while being held a sufficient time to receive the testing results fromthe lab before the product is shipped. Thus, it should be appreciatedthat any particular day of the week or any particular shift could beused in place of Friday in step S165, so long as sufficient time isallowed to pass before step S170 is carried out relative to suchpackaged food products. In particular, if the food was packaged onFriday or other designated time for such tests, operation continues tostep S170. Otherwise, operation jumps to step S180.

In step S170, the packaged food product(s) are stored until Monday, orfor some other necessary or desired interval, while awaiting receipt ofthe test results showing that the food processing product is acceptable.Next, in step S175, if no contamination is found, the packaged foodproduct(s) are prepared for shipping from the food processing facility.Otherwise, if contamination is found in any of the packaged foodproduct(s) tested, appropriate steps may be taken to identify thesingle-line food processing room(s) within which the contaminatedproduct was processed, to segregate all product from that room(s), andto take appropriate remedies or action to identify the source of thecontamination and to properly dispose of or subject to additionallethality treatment the contaminated product and facilities. Operationthen jumps to step S185.

In contrast, in step S180, the uninspected packaged food product(s) areprepared for immediate shipping from the food processing facility. Then,in step S185, the packaged food product(s) are shipped from the foodprocessing facility to either a downstream food processing facility, adownstream warehouse or other storage location, a retailer or the like.Operation then continues to step S190, where operation of the methodends.

FIGS. 9 and 10 are a flowchart outlining one exemplary embodiment of amethod for controlling movement of personnel within a food processingfacility according to this invention. As shown in FIGS. 9 and 10,operation of the method begins in step S200, and continues to step S205,where a person wishing to enter the semi-secure or secure areas of thefood processing facility dons appropriate footwear, such as, forexample, rubber boots. Then, in step S210, the person proceeds through asanitizing station to enter a buffer area. In the buffer area the personwill be able to don an appropriate uniform. Next, in step S215, adetermination is made which areas of the food processing facility theperson wishes to enter. Operation then proceeds to step S220.

In step S220, a determination is made whether the person wishes to enterthe food delivery or food processing areas, i.e., the secure areas ofthe food processing facility. If so, operation continues to step S225.Otherwise, operation jumps to step S240. In step S225, a determinationis made whether the person has completed appropriate food safetytraining. If not, operation continues to step S230. Otherwise, operationjumps to step S235. In step S230, because the person has not completedthe appropriate food safety training to enter the food delivery or foodprocessing areas, the person is denied access to these areas. Operationthen returns to step S220. In contrast, in step S235, the person, havingcompleted the appropriate food safety training, and thus beingauthorized to enter the food delivery or food processing areas, dons afull-body or other secure area uniform. Operation then jumps to stepS245. In further contrast, in step S240, because the person does notwish to enter the food delivery or food processing areas, the personputs on a food transfer-type, or semi-secure area-type, uniform.Operation then proceeds to step S245.

In step S245, the person proceeds from the buffer area to the authorizedarea(s) of the food processing facility the person, assuming the properuniform is being worn, wishes to visit. Next, in step S250, adetermination is made whether the person wishes to enter the packagedfood receiving area, the food delivery area, or the food processingareas. If so, operation continues to step S255. Otherwise, operationjumps to step S260. In step S255, the person proceeds to a second bootsanitizing station to enter the desired area of the food processingfacility. Operation then proceeds to step S260.

In step S260, a determination is made whether the person wishes to exitthe food processing facility completely or whether the person wishes tochange to a different area of the food processing facility. If not,operation returns to step S260. Otherwise, if the person wishes tochange which area of the food processing facility the person is in,operation continues to step S265. Else, if the person wishes to exit thesecure and semi-secure areas, operation jumps to step S280. In stepS265, a determination is made whether the person wishes to re-enter thefood delivery or food processing areas from the buffer area or one ofthe other semi-secure areas of the food processing facility, such as thetreatment room, the receiving area, the packaged food receiving area,the cold storage area or the like. If so, operation continues to stepS270. Otherwise, operation jumps to step S275. In step S270, the personputs on a new full-body uniform and recycles the old full-body uniformfor sanitation. Then, in step S275, the person proceeds to theappropriate boot sanitizing station. For example, if the person isleaving the food delivery or food processing areas into one of thesemi-secure areas, the person will proceed through a footwear sanitizingstation. Likewise, if the person is proceeding from the packaged foodreceiving area to another one of the semi-secure areas, the person willproceed through the appropriate footwear sanitizing station. Operationthen returns to step S260.

In contrast, in step S280, the person proceeds through the footwearsanitizing stations necessary to reach the unsecured areas of the foodprocessing facility. Then, in step S285, the person recycles forsanitation whatever uniform the person is currently wearing. Next, instep S290, a determination is made whether the person wishes to re-enterthe food processing area. This will occur when the person is returningfrom a visit to the restroom or from lunch or some other break. If so,operation returns to step S210. Otherwise, operation continues to stepS295, where operation of the method stops.

FIG. 11 is a flowchart outlining one exemplary embodiment of a methodfor cooling and ventilating a single-line food processing room accordingto this invention. As shown in FIG. 11 beginning in step S300, operationof the method continues to step S305, where air is drawn from outside ofthe food processing facility through an air inlet, through a bacterialgrade filter, such as a HEPPA air filter or other appropriate filterdevice and into a plenum that supplies at least the food processingrooms. Then, in step S310, the filtered outside air is allowed to passthrough a second filter into the associated single-line food processingroom to provide twice filtered make-up air as needed. Next, in stepS315, air is withdrawn from the associated single-line food processingroom into a dedicated ventilating and air conditioning (VAC) enclosure.Operation then continues to step S320.

In step S320, the temperature and humidity of the withdrawn air arereduced to near or below freezer-range temperature and humidity. Next,in step S325, the withdrawn and cooled air is returned to thesingle-line food processing room at high velocity to create higher thanambient air pressure in the single-line food processing room andmaintain room temperature near freezing. Then, in step S330, due to thehigher than ambient air pressure in the single-line food processingroom, high pressure air is unidirectionally exhausted from thesingle-line food processing room through the openings in the walls thatlead to the delivery and receiving areas. Operation then continues tostep S335.

In step S335, a determination is made whether the air in the single-linefood processing room needs to be vented rather than recirculated. Ifnot, operation returns to step S315. Otherwise, operation continues tostep S340, where the high pressure air is exhausted from the single-linefood processing room to outside of the food processing facility via oneor more damper controlled ducts that direct the exhausted air away fromthe air inlet that is used to draw air from outside of the foodprocessing facility into the bacterial grade filter. Operation thenreturns to step S310.

It should be understood that the order of the steps of each of theforegoing methods is not limited to the order described and illustrated,but in exemplary embodiments can include any such step in anyappropriate order which does not preclude or compromise other steps ofthe method.

The above-outlined various exemplary embodiments of various structures,systems and techniques are each useful in reducing the ability ofListeria or other pathogenic microorganisms to enter food processingfacilities, or migrate between, or cross contaminate, different foodprocessing devices or food processing device lines. Thus, each of thevarious structures, systems and methods described herein are separatelyuseful. When such structures, systems and methods are combined intovarious combinations, the ability of Listeria and other pathogenicmicroorganisms to invade or migrate between different food processingdevices and/or lines is even further reduced. Thus, it should beappreciated that food processing facilities, systems and methodsaccording to this invention do not need to use all or even a pluralityof the various structures, systems and techniques disclosed herein.

While this invention has been described in conjunction with theexemplary embodiments outlined above, various alternatives,modifications, variations, improvements, and/or substantial equivalents,whether known or that are or may be presently unforeseen, may becomeapparent to those having at least ordinary skill in the art.Accordingly, the exemplary embodiments of the invention, as set forthabove, are intended to be illustrative, not limiting. Various changesmay be made without departing from the spirit and scope of theinvention. Therefore, the invention is intended to embrace all known orearlier developed alternatives, modifications, variations, improvementsand/or substantial equivalents.

What is claimed is:
 1. A food processing facility for previously processed food products, the facility comprising: a first region corresponding to a semi-secure area; a second region corresponding to a secure area accessible from the first region, the second region including a plurality of separate isolated single-line food processing rooms accessible from the semi-secure area, each single-line food processing room being isolated from the other single-line food processing rooms and including a single set of serially-connected food processing elements which is independent of food processing devices in any other single-line food processing room.
 2. The food processing facility of claim 1, wherein the plurality of separate isolated single-line food processing rooms are arranged in an approximate operationally parallel relation.
 3. The food processing facility of claim 1, wherein previously processed food products includes cooked food products.
 4. The food processing facility of claim 1, further comprising a treatment room in the first region for a post-lethality treatment of a previously cooked food product.
 5. The food processing facility of claim 1, wherein the first region and second region are separated by a sanitizing station.
 6. The food processing facility of claim 1, wherein a sanitizing station is located between the first region and second region.
 7. The food processing facility of claim 1, wherein the serially-connected food processing elements include a slicing machine and a packaging machine.
 8. The food processing facility of claim 1, further comprising an unsecured area accessible from the semi-secure area.
 9. The food processing facility of claim 1, further comprising a semi-secure packaged food receiving area separated from the second region, and each of the plurality of food processing rooms having a passage to a packaged food receiving area.
 10. The food processing facility of claim 1, further comprising a buffer area.
 11. The food processing facility of claim 1, wherein the separate isolated single-line food processing rooms are substantially sterile.
 12. A food processing facility for previously processed food products, the facility comprising: a semi-secure area; a secure area accessible from the semi-secure area by a passage, the secure area including a delivery area and a plurality of separate isolated single-line food processing rooms accessible by a passage from the delivery area, each single-line food processing room including a single set of serially-connected food processing elements which is independent of food processing devices in any other single-line food processing room and each single-line food processing room is isolated from the other single-line food processing rooms; and a passage for delivery of food products from each single-line food processing room to a receiving area.
 13. The food processing facility of claim 12, wherein the separate isolated single-line food processing rooms are substantially sterile.
 14. The food processing facility of claim 12, wherein the receiving area is a packaged food receiving area.
 15. The food processing facility of claim 12, wherein the delivery area is substantially sterile.
 16. The food processing facility of claim 12, wherein the receiving area is a lower atmospheric pressure and temperature than each single-line food processing room.
 17. The food processing facility of claim 12, wherein each single-line food processing room is a higher internal pressure and colder temperature than the delivery area.
 18. A food processing facility for previously processed food products, the facility comprising: a semi-secure area; a secure area joined by a passage to the semi-secure area, the secure area including a delivery area and a plurality of separate isolated single-line food processing rooms each joined by a passage to the delivery area, each single-line food processing room including a single set of serially-connected food processing elements which is independent of food processing devices in any other single-line food processing room.
 19. The food processing facility of claim 18, wherein the single-line food processing room includes a slicing machine.
 20. The food processing facility of claim 18, wherein the single-line food processing room includes a packaging machine.
 21. The food processing facility of claim 18, wherein each single-line food processing room includes two or more serially connected food processing elements.
 22. The food processing facility of claim 18, wherein an unsecured area is joined by an additional passage to the semi-secure area.
 23. A food processing facility for previously processed food products, the facility comprising: a first region corresponding to a unsecure area accessible from an outside or a second region; the second region corresponding to a semi-secure area accessible from the first region, the second region including at least a portion of a delivery area; a third region corresponding to a secure area accessible from the second region, the third region including a plurality of separate isolated single-line food processing rooms accessible from the delivery area, each single-line food processing room including a single set of serially-connected food processing elements which is independent of food processing devices in any other single-line food processing room.
 24. The food processing facility of claim 23, wherein the second region comprises a food receiving area and a delivery area.
 25. The food processing facility of claim 23, further comprising a treatment room in the first region for lethality treatment of a food product.
 26. The food processing facility of claim 23, further comprising a sanitizing station between at least two of the regions.
 27. The food processing facility of claim 23, wherein the serially-connected food processing elements include a slicing machine and a packaging machine.
 28. The food processing facility of claim 27, further comprising of a transfer conveyor to move processed food products from the slicing machine to the packaging machine.
 29. The food processing facility of claim 23, further comprising a semi-secure packaged food receiving area, and each of the plurality of single-line food processing rooms having a passage to the semi-secure packaged food receiving area.
 30. The food processing facility of claim 23, further comprising a buffer area.
 31. A food processing facility comprising a plurality of isolated single-line food processing and packaging rooms, each said room having a single set of serially-connected food processing elements which is independent of food processing devices in any other single-line food processing and packaging room from the plurality of isolated single-line food processing and packaging rooms. 